CYCLOTRON

M.Karthikeyan G.Amit Kumar S.Anand ram C.G.Dhatheshvar Shanmugaraj M.S.Karthikeyan L.Mohan Kumar Maharaja Mariappan

Go-Green Approach

1.Vehicle configuration Requirement : Three wheel not in straight line , capable of carrying two riders, maximum vehicle dimension is 90inch x 50 inch. Design : Tadpole configuration (More stable than delta, compact framework) with overall dimension of 84.6inch x 33.4 inch. 2.Seating Arrangement Requirement : Maximum seating height limited to 36 inches , rider height up to 190.3 cm. Design : In-line seating arrangement (Ergonomic driving condition, rear rider view, adjustable rear seat ). 3.Chassis Structure Requirement : Must be made up of steel and a minimum diameter of 1 inch, weight of rider 115 kg + PMDC/BLDC motor) Design : Rectangular box section chassis with hexagonal framework for mounting motor, seat and KERS.

4.Brakes Requirement : Positive locking brakes on all wheels, hydraulic/non-hydraulic brakes, must be mounted on the wheel and not on drive axle. Design : Front-Mechanical Disc brake ( Controlled by the front rider) Rear-Hand brake ( Controlled by the rear rider) 5.Steering Requirement : Any type of steering , rotating parts must be properly covered. Design : Ackermann steering , split handlebar ( Better handling, Turning radius =2.25m) 6.Seat Requirement : Seat must support the thigh and the entire torso of the driver. Design : Front-Ergonomic seat with adjustable hand rest Rear-Adjustable seat with back rest 7.Power Requirement : Must be driven by both human and electric power. Design : Pedal driven , 400 watts BLDC motor.

8.Suspension Requirement : Withstand shock Design : Coil Spring ( Based on reaction and articulation of wheel with shackle arrangement) 9. Safety Requirement : Kill switch should be accessible to both riders, roll-over protection, frontal impact protection. Design : Independent kill switches for both driver, roll-over cage , front bumper. ADDITIONAL FEATURES -Headlight, Indicators, Taillight, Horn, Rear-view mirror -Adjustable roof -Mechanical KERS system spiral torsion spring for energy storage(engaged and disengaged according to need) - Accelerometer , Battery level indicator

Vehicle specifications
Overall Dimensions : 2150 x 850 x
Weight : Gross weight = 275 kg Electricals Motor BLDC Motor, 400W , 24V

mm
Kerb weight = 45 kg (approx)

Battery 24V (2 Nos) , connected in series

Headlight ,Tail light, Indicators

Steering

Type : Ackermann Steering, Split handlebar Turning Radius : 2.25 m

Seating

Front-Ergonomic seat with adjustable hand rest

Rear-Adjustable seat with back rest

Suspension

Rear: Coil spring with telescopic shock absorber. Stroke Length = 5 cm

Front : Coil spring Stroke Length = 12 cm Brake Front : Mechanical disc brake Rear : Hand operated shoe brake

Wheels and Tyres

Rim diameter : 22 inch Wheel diameter : 24 inch

MOTOR POWER CALCULATIONS CONSIDERING SURFACE ROADS:

DRIVING FORCE CALCULATIONS: Gross vehicle weight, w : 270kg : 2648.7N Maximum vehicle speed, v = 20 km/hr = 5.55m/s Acceleration: assume 20km/hr in 20 seconds a = v/20 = 5.55/20 =0.2775m/s2 External driving force, E.D.F = gross vehicle weight acceleration = w 0.643 = 270*0.277 = 74.79N

RESISTANCE CALCULATIONS: AIR RESISTANCE: Ra= 0.0386**Cw*A*(v + vo) - Density of air = 1.23 kg/m Cw- Drag co-efficient= 0.4 Frontal area= 1.287m Vo- Wind speed, assume= 0 Ra=0.0386*1.23*0.4*1.287*20 = 8.07126N ROLLING RESISTANCE: Rr= f*m*g* cos d f- co-efficient of rolling resistance= 0.007 d=0 Rr= 0.007*270*9.81 =18.5409N Power due to rolling resistance= 18.5409*11.11 =205.98W

GRADIENT RESISTANCE: Rg=0 Case 1: when running on manual power (assume speed=20Km/hr) S=ut+1/2*at2 S=0+0.5*0.277*202 S=55.4m Work done = F*s = 4143.366 Nm Power output = Work done/Time taken = 207.91W Case 2: When running on motor (let speed be 40km/hr) S=ut+1/2*at2 S=0+0.5*0.277*402 S=221.6m Work done = F*s = 16573.464 Nm Power output = Work done/Time taken = 414.33W Total power = 205+414+27.67 = 647.57W

KERS

KERS Calculation Material=1070 carbon steel E= 2.06 x 105 Max shear stress=1200 Mpa Torque produce= 6.322*11.636 Nm B = 6.35 mm A = 186mm = 1 rev S = ( 6 x M )/( b x 2 ) Mpa Bt2 =6 x 6.322 x 11.636/1200 x 1000 x 1000 =3.678 x 10-7 m3 =367.81mm3 T=7.61mm L = (3.14 x E x b x 3 x ) / ( 6 x M) mm L=16413.278/4=4103.3195mm ODF = (2xL) / (3.14x((((A2+1.27Lt)-A)/2t)-) ODF = 371.82mm

Front Impact

Side Impact

Von-Mises Stress

Front seat Cushioned seat with adjustable hand rest

Rear seat Adjustable seat with back rest

Roof Adjustable roof with aerodynamic curve

Dashboard Accelerometer and Battery level indicator

Fancy headlights and LED tail-lights

Coil spring suspension for damping shocks

Week 1 2 3 4 5 6 7

Dates 23 July to 29July 30 July to 5 Aug 6 Aug to 12Aug 13 Aug to 19 Aug 20 Aug to 26 Aug 27 Aug to 2 Sept 3 Sept to 9 Aug Material Purchase

Work scheduled

Fabrication of chassis Fabrication of Steering Parts Assembly of Steering system Fabrication of Transmission System Assembly of Transmission System Fabrication and Assembly of Mechanical KERS

8
9 10 11

10 Sept to 16 Sept

Full Body Assembly including the Wheel

17 Sept to 23 Sept Connections of Brakes and Electric power source 24 Sept to 30 Sept Aerodynamics and Finishing 1 Oct to 7 Oct Test Driving and trouble shooting

Target Date of Completion : 7th Oct Cost Estimation

S.No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Part Name Free wheel Foot Pedal set Crank Arm set Crank Bottom set Mudguard Spring seat Wheel set Sprocket Miscellaneous(Nuts,Bolts and Paint) Suspension spring Cost (Rs.) 90 120 300 150 270 320 900 360 400 350

11. 12.

Epicycle gear train Chain

1200 250 ( 5 meters )

Assembly-Manufacture Layout
Welding of chassis Assembly of chassis with suspension Brake fitting along with connection of brake cables with levers Gear and sprocket assembly on chassis Pedal fitting

Mud-guards ,chain fitting and other machine parts covering

Chain fitting

Mounting of motor , KERS and free wheel

Ergonomics checking

Wheel assembly

Handle and seat assembly

Drive test , brake test and electricals test

Complete product

Painting, oiling and greasing